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F 9

T P

- 7 A

2 6 2 - C

L-

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

66 DIRECT CLUTCH FRICTION PLATES
67 DIRECT CLUTCH STEEL PLATES
68 DIRECT CLUTCH BACKING PLATE

"SELECTIVE"

SNAP RING

Figure 120

F 9

T P

- 7 A

2 6 2 - C

L-

Direct Clutch Clearance Should Be

1.15 - 2.06mm (.045" - .081")

Selective Snap Rings Available

1.65-1.75mm (.065" - .069")
1.88-1.98mm (.074" - .078")
2.10-2.20mm (.083" - .087")

Figure 121

Summary of Contents for FORD 4R100

Page 1: ...SION DISASSEMBLY 41 COMPONENTREBUILD SECTION TRANSMISSION CASE ASSEMBLY 55 FRONT AND REAR PLANETARY CARRIERS 64 FORWARD CLUTCH HOUSING 66 DIRECT CLUTCH HOUSING 69 FORWARD DIRECT SUN SHELL SUB ASSEMBLY...

Page 2: ...ers contained in this booklet have been carefully compiled from industry sources known for their reliability but ATSG does not guarantee its accuracy Copyright ATSG 2003 Updated October 2003 The Ford...

Page 3: ...y F Jun G Jul H Aug J Sep K Oct L Nov M Dec XW4P AC 5 5G G RJL B BD 9C17 004361 004361 6520 4 X 4 4 X 4 1 2 3 4 Build Date Year Month Day Serial Number Transmission Model Assembly Part Number Prefix A...

Page 4: ...ForwardClutch Multi disc Low ReverseClutch Multi disc OverdriveRollerClutch IntermediateSprag LowRollerClutch Overdrive Forward Reverse P R N D 2 1 Figure 2 Figure 3 Vehicles equipped with the 4R100...

Page 5: ...d Mod Mod Mod Mod Mod Mod On On Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off Off ON ON ON ON ON ON ON ON ON ON Int Clut Int Band O D Roller Low Roller SS1 SS2 CCS SOLENOIDS TCC EPC...

Page 6: ...trategy does not allow 4th gear to engage underany conditions Transmission Fluid Temperature Sensor TFT reading must be up to operating temperature Specific Operation For Diesel See Page 7 GASOLINE EN...

Page 7: ...speed at a faster or slower rate RPM Control is used for This is the recommended method of elevating idle speed for PTO operations RPM Control mode can be activated from in cab and can be programmed...

Page 8: ...unted on the accelerator pedal inside the vehicle and detects the position of the accelerator pedal and sends this information as a varying voltage signal to the PCM The PCM then uses the monitored vo...

Page 9: ...changed to a thrust bearing as shown in Figure 11 We have provided you with the resistance reading and the OEM part number for the output shaft speed sensor Refer to Figure 10 for output shaft speed s...

Page 10: ...r that is alsointernal Note All testing that we have provided for you is done with a DVOM set to the ohms position and all tests are performed with the ignition switch in the OFF position 1 Testing th...

Page 11: ...D 270 W 270 W 270 W 1 7 8 2 9 3 10 4 11 5 12 6 View looking into DTR Sensor 12 11 10 9 8 2 3 4 5 6 1 7 View looking into DTR Sensor harness connector terminal side P 1 2 R N D P 1 2 R N D P 1 2 R N D...

Page 12: ...ase connector and the vehicle harness We have also provided a chart that will give you the function of each and the ohms readings you should see on each of the solenoids and the TFT sensor Note All te...

Page 13: ...PCM Transmission Fluid Temp Sensor Transmission Fluid Temp Sensor Signal Return Not Used Not Used Not Used 71 97 71 97 11 6 54 20 37 91 81 1 27 28 53 37 91 81 71 97 71 97 SOLENOID BODY CONNECTOR 1 6...

Page 14: ...ital Transmission Range Sensor Exhaust Back Pressure Engine Coolant Temperature Exhaust Pressure Regulator Fuel Pulse Width Flash EPROM Power Supply Glow Plug Control Duty Cycle Glow Plug Intake Air T...

Page 15: ...engage MAP sensor orcircuit open shorted to ground or to 5V MAP sensor signal higher or lower than expected or no response due to vacuum hose circuitdamaged disconnectedorrestricted MAP sensor out of...

Page 16: ...ar selection depending on failure mode and transmission range selector position Refer to shiftsolenoidoperationchart Improper gear selection depending on failure mode and transmission range selector p...

Page 17: ...osition Refer to shiftsolenoidoperationchart Improper gear selection depending on failure mode and transmission range selector position Refer to shiftsolenoidoperationchart Improper gear selection dep...

Page 18: ...al operating temperature and rerun On Board Diagnostics BPP Brake Pedal Position switch not actuated during KOER test Failed on or not connected TCC will not engage at less than one third throttle ope...

Page 19: ...has exceeded270 F Failed Off No third gear engine brakinginO D cancel Failed On Third gear engine braking in O D range Coast clutch may be damaged causing eventual failure Short circuit causes minimu...

Page 20: ...Always On Controlled by PCM D Selector Lever Position Actual Gear Obtained PCM Gear Commanded 2 1 1st 2nd 3rd 4th SHIFT SOLENOID A ALWAYS OFF 4 4 3 3 2 2 2 2 2 2 2 1 D Selector Lever Position Actual G...

Page 21: ...g the line pressure test Figure 24 NOTE Perform the line pressure test before performing the Stall test If the line pressure is low at Idle DO NOT perform the Stall test or further transmission damage...

Page 22: ...PTO and PTO ValveBodyToCaseSpacerPlates MAIN VALVE BODY A passage was added on the Upper Side of the Main Valve Body on PTO versions as shown in Figure 29 to supply Line Pressure to the 3 4 Shift Val...

Page 24: ...AIN SPACER PLATE NON PTO MODELS ONLY F81P DA F81P DA 97 97 12 12 CENTRAL LUBE ORIFICE I D 1 DOVE TAIL PART NUMBER F81Z 7A008 DA AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 24 Co...

Page 25: ...EGULATOR VALVE F81P BA F81P BA 98 98 6 6 CENTRAL LUBE ORIFICE 4R100 MAIN SPACER PLATE PTO MODELS ONLY I D 2 DOVE TAILS PART NUMBER F81Z 7A008 BA Figure 27 AUTOMATIC TRANSMISSION SERVICE GROUP Technica...

Page 27: ...ER SIDE 4R100 MAIN VALVE BODY PTO MODELS ONLY Figure 29 PASSAGE ADDED TO FEED LINE PRESSURE TO THE 3 4 SHIFT VALVE AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 27 Copyright 2003...

Page 28: ...NLY Figure 30 Ford Ford RFF61P 7A092 AB RFF61P 7A092 AB Du Page Du Page 09328 09328 6 6 I D ROUGH FORGING NUMBER OF RF F6 WHICH INDICATES 96 LOW REVERSE CLUTCH AUTOMATIC TRANSMISSION SERVICE GROUP Tec...

Page 29: ...WHICH INDICATES 98 PASSAGE ADDED LEADING TO THE EXHAUST IN THE LOWER VALVE BODY LOW REVERSE PASSAGE RE MOVED FROM SPRING SIDE OF 3 4 SHIFT VALVE LOWER SIDE 4R100 MAIN VALVE BODY PTO MODELS ONLY Figure...

Page 30: ...8 09828 5 5 Du Page Du Page Ford Ford 4R100 LOWER VALVE BODY NON PTO MODELS ONLY Figure 32 I D ROUGH FORGING NUMBER OF RF F6 WHICH INDICATES 96 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service I...

Page 31: ...Ford Ford 4R100 LOWER VALVE BODY PTO MODELS ONLY EXHAUST PASSAGE ADDED FROM COAST CLUTCH VALVE TO 3 4 SHIFT VALVE Figure 33 I D ROUGH FORGING NUMBER OF RF F8 WHICH INDICATES 98 AUTOMATIC TRANSMISSION...

Page 32: ...LY 4R100 LOWER VALVE BODY SPACER PLATE Figure 34 HOLE ADDED TO CONNECT WITH EXHAUST PASSAGE IN LOWER VALVE BODY I D 1 DOVE TAIL I D 2 DOVE TAILS AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service...

Page 33: ...UTCH SOLENOID FROM SOLENOID 4 COAST CLUTCH SOLENOID FROM 2 3 SHIFT VALVE FROM 2 3 SHIFT VALVE FROM CB15 2 3 SHIFT VALVE TO CB3 COAST CLUTCH TO CB3 COAST CLUTCH TO CB7 OVERDRIVE CLUTCH TO CB7 OVERDRIVE...

Page 34: ...The Converter Clutch Control Valve s rear spool was enlarged approximately 070 There was alsoabushingandvalveaddedtotheendofthevalvetrainasshowninFigure36 A hole was added to the pump cover to connec...

Page 35: ...THE SPOOL ON THE VALVE LAND SHOWN ABOVE WERE INCREASED ON PWM VERSIONS THE BORE IN THE PUMP COVER WAS ALSO ENLARGED APPROXIMATELY 070 TO ACOMMODATE THE CHANGES IN THE DIAMETER OF THE VALVE Figure 36...

Page 36: ...NLY LUBE ORIFICE 090 CONVERTER RELEASE ORIFICE 070 CONVERTER REGULATOR VALVE CONVERTER CLUTCH CONTROL VALVE PRESSURE REGULATOR VALVE RETAINER Figure 37 AUTOMATIC TRANSMISSION SERVICE GROUP Technical S...

Page 37: ...AGE 036 ADDED AIR BLEED CONVERTER RELEASE ORIFICE OMITTED HOLE ADDED TO CONNECT TO HOLE IN CONTROL VALVE BUSHING CONVERTER REGULATOR VALVE CONVERTER CLUTCH CONTROL VALVE PRESSURE REGULATOR VALVE RETAI...

Page 38: ...DELS Figure 39 CB14 CB9 CB1 CB6 BS3 BS1 CB7 CB8 EPC Ball And Spring Requires Eight 5 16 Diameter Rubber Checkballs Plus The EPC Ball And Spring As Shown Above AUTOMATIC TRANSMISSION SERVICE GROUP Tech...

Page 39: ...B Du Page Du Page 09328 09328 6 6 CB16 1 4 Rubber CB15 5 16 Rubber X CB13 5 16 Rubber BS2 1 4 Rubber 4R100 VALVE BODY CHECKBALL LOCATIONS NON PTO AND PTO MODELS AUTOMATIC TRANSMISSION SERVICE GROUP Te...

Page 40: ...tion 40 Copyright 2003 ATSG Copyright 2003 ATSG Low Reverse Clutch Intermediate Clutch Intermediate Lube Overdrive Clutch Coast Clutch Forward Clutch Direct Clutch AIR PRESSURE CHECKS Figure 41 Figure...

Page 41: ...C17 1 Remove the turbine shaft from the transmission as shown in Figure 42 Inspect the spline area on both ends and set aside for final assembly 2 Remove the two Digital Transmission Range sensor reta...

Page 42: ...ody retaining nuts and 11 bolts as shown in Figure 49 and removeaccumulatorvalvebody 4 Set the accumulator valve body aside for the componentrebuildsection 5 Remove two main valve body retaining nuts...

Page 43: ...RETAINING NUT 186 SPACER PLATE TO MAIN VALVE BODY GASKET 187 SOLENOID SCREEN ASSEMBLY TRANSMISSION DISASSEMBLY Bottom Pan Components 7 Remove the solenoid body retaining nut and the 9 retaining bolts...

Page 44: ...emove the manual intermediate servo piston as shown in Figure 54 by tapping gently on the piston with a rubber mallet to release it from casebore 16 Removetheeightcheckballsfromtheircase pockets assho...

Page 45: ...9 8 KXV 9 8 KXV 9 8 KXV 9 8 KXV 9 8 KXV 9 8 KXV 9 8 KXV 9 8 KXV 9 8 1 Remove the nine oil pump assembly retaining bolts as shown in Figure 57 2 Remove and discard the sealing washers from theninepumpr...

Page 46: ...Components Cont d 7 Remove the coast clutch housing as shown in Figure 58 and set aside for component rebuild section Note There are three different versions of the coast clutch housing which we will...

Page 47: ...UST BEARING TRANSMISSION DISASSEMBLY Internal Components Cont d Figure 62 Figure 61 10 Remove the overdrive carrier and center shaft assembly as shown in Figure 60 and set aside for the componentrebui...

Page 48: ...re 64 16 Removethecentersupportassembly asshown inFigure64 andsetasideforthecomponent rebuildsection 17 Remove the number 6 thrust washer center support to direct clutch housing as shown in Figure 64...

Page 49: ...89T 70010 E TRANSMISSION DISASSEMBLY Internal Components Cont d Figure 66 52 INTERMEDIATE CLUTCH FRICTION PLATES 53 INTERMEDIATE CLUTCH STEEL PLATES 54 INTERMEDIATE CLUTCH BACKING PLATE 54 52 53 20 In...

Page 50: ...BER 10B THRUST WASHER 104 REAR PLANETARY CARRIER ASSEMBLY 106 OUTPUT SHAFT SNAP RING 107 REAR PLANETARY RING GEAR 112 NUMBER 12 THRUST BEARING RING GEAR TO INNER RACE 22 Remove the snap ring retaining...

Page 51: ...erasshown inFigure71 fromthegrooveincase 28 Removethesnapringfromcase asshownin Figure72 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 51 Figure 70 Continued on Page 52 Copyright...

Page 52: ...e plate as shown in Figure 73 30 Rotate transmission in fixture so output shaft is facing up as shown in Figure 74 31 Remove the extension housing retaining bolts and housing as shown in Figure 74 32...

Page 53: ...pyright 2003 ATSG 33 Notice that the 2WD version has a speed sensor reluctor wheel that must be pressed off and on if necessary to replace as shown in Figure 75 34 Remove and discard the extension hou...

Page 54: ...move and discard the lube orifice plug from rear of case as shown in Figure 78 LOW ROLLER CLUTCH INNER RACE RETAINING BOLTS 5 LUBE ORIFICE PLUG OUTPUT SHAFT AND PARK GEAR NUMBER 13 THRUST BEARING 5G B...

Page 55: ...the 5 low roller clutch inner race bolts as shown in Figure 79 41 Rotate the transmission in fixture so the bell housing is facing up as shown in Figure 80 42 Remove the low roller clutch inner race t...

Page 56: ...sitioned in the 5 o clock position when it is installed The 6 o clock position is the bottomof the case 14 Install the low roller clutch inner race in case as shown in Figure 86 and install two nuts o...

Page 57: ...TOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 57 Figure 85 Figure 86 Figure 87 Copyright 2003 ATSG 113 114 117 115 116 15 Tighten the nuts to compress the reverse clutch return spri...

Page 58: ...in the direction shown in Figure 88 19 Install the output shaft into the case as shown in Figure 88 Note We have illustrated the 4WD version in Figure 88 COMPONENT REBUILD Transmission Case Assembly C...

Page 59: ...behind the case as shown in Figure 91 22 Install the parking rod guide plate as shown in Figure 90 23 Install the two park rod guide plate retaining bolts and torque to 16 27 N m 12 20 ft lb Note Ensu...

Page 60: ...opyright 2003 ATSG Figure 92 Figure 93 25 Installnewextensionhousinggasketoncase surface as shown in Figure 92 26 Install the 4WD extension housing as shown in Figure 92 Note The 4R100 unit requires a...

Page 61: ...nformation 61 Copyright 2003 ATSG FORD 4R100 6 8L AND 7 3L 2 WHEEL DRIVE SHOULDER SHOULDER ADDED BOSS 4R100 TYPICAL 4 WHEEL DRIVE ALL OTHER 4R100 2 WHEEL DRIVE APPLICATIONS E4OD WITHOUT LUBE PLUG NO S...

Page 62: ...tating clockwise as shown in Figure 97 until fully seated Note Reverse clutch hub should freewheel clockwiseand lockcounter clockwiseafter installationin case 33 Install the reverse clutch Wave plate...

Page 63: ...sensitive and may vary from the illustration Astack upclearancemeasurementis not required for the reverse clutch 37 Install the number 12 thrust bearing and rear ring gear into case as shown in Figure...

Page 64: ...e above conditionsexist 3 Set the carriers aside for final assembly Both planetary carriers are model sensitive parts and may contain a 4 pinion carrier or a 6 pinion carrier as shown in Figures 100 1...

Page 65: ...ORWARD CLUTCH PISTON APPLY RING 77 FORWARD CLUTCH PISTON BELLVILLE RETURN SPRING 78 FORWARD CLUTCH RETURN SPRING SNAP RING 79 FORWARD CLUTCH APPLY PLATE 80 FORWARD CLUTCH WAVE PLATE 81 FORWARD CLUTCH...

Page 66: ...for any wear and ordamage Note Ensurethattheairbleedballinthe forwardclutchpistonisfreeandoperational See Figure 104 4 Remove and discard the forward clutch inner andouterseals 5 Place the forward clu...

Page 67: ...clutch housing with a twisting motion using care not to damage seals See Figure 104 9 Install the forward clutch piston apply ring into groove on top of piston See Figure 104 Forward Clutch Housing Co...

Page 68: ...h a friction plate as shown in Figure 107 until the proper amountof platesare installed Note The number of forward plates is model sensitive and may vary from the illustration 15 Install the forward c...

Page 69: ...SSEMBLY 58 INTERMEDIATE SPRAG OUTER RACE THRUST WASHER NUMBER 7 59 DIRECT CLUTCH HOUSING ASSEMBLY 57 DIRECT CLUTCH HOUSING FRONT SIDE EXPLODED VIEW DIODE ONE WAY CLUTCH ASSEMBLY DIRECT DRUM FOR DIODE...

Page 70: ...CLUTCH PISTON ASSEMBLY 63 DIRECT CLUTCH PISTON RETURN SPRING ASSEMBLY 64 DIRECT CLUTCH PISTON RETURN SPRING SNAP RING 66 DIRECT CLUTCH FRICTION PLATES 67 DIRECT CLUTCH STEEL PLATES 68 DIRECT CLUTCH B...

Page 71: ...fit back on all models INPUT SUN SHELL NOTE Using the early style sun shell Requires that you use the number 8A thrust washer on direct drum and the direct drum that accepts it Figure 111 Figure 112 E...

Page 72: ...OUTER RACE THRUST WASHER NO 7 59 DIRECT CLUTCH HOUSING ASSEMBLY 58 57 59 COMPONENT REBUILD Direct Clutch Housing Cont d 5 We have illustrated the Diode style one way intermediateclutchand theassociate...

Page 73: ...on asshownin Figure116 Note Outer sprag race should freewheel counter clockwiseandlockclockwise as shown inFigure116 10 Turn the direct clutch housing over on a flat work surface as shown in Figure 11...

Page 74: ...Figure 119 Note RefertoFigures111and112forthe informationregarding the 8Athrust washer and compatableparts 18 Install the direct clutch pack beginning with a steel plate and alternating with a fricti...

Page 75: ...LUTCH FRICTION PLATES 67 DIRECT CLUTCH STEEL PLATES 68 DIRECT CLUTCH BACKING PLATE 67 66 69 68 SELECTIVE SNAP RING Figure 120 F 9 T P 7 A 2 6 2 C A L 2 0 Fo rdFo rd Direct Clutch Clearance Should Be 1...

Page 76: ...u will have to install the number 8A thrust washer if you require one 2 Place the completed direct clutch housing on a flat work surface in the direction that is shown in Figure 123 3 Install the comp...

Page 77: ...R AND HUB ASSEMBLY NUMBER 8C THRUST WASHER 72 59 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 77 Copyright 2003 ATSG Copyright 2003 ATSG F 9 T P 7 A 2 6 2 C A L 2 0 Fo rdFo rd 59...

Page 78: ...ASSEMBLY 91 72 59 Copyright 2003 ATSG COMPONENT REBUILD 7 Installthenumber10Athrustbearingontothe forwardplanetarycarrier inthedirectionthat isshowninFigure127 andretainthebearing withTrans Jel 8 Tur...

Page 79: ...CT ASSEMBLY Figure 130 Figure 131 COMPONENT REBUILD 10 Installthepropersungearshellovertheentire assembly as shown in Figure 130 11 Holdthecompletedassemblytogetherandroll completeassemblyoversothatit...

Page 80: ...e cleaning solution and blow dry with compressedair 3 Inspect all center support parts thoroughly for any wear and ordamage 4 Remove and discard the two center support directclutchsealingrings See Fig...

Page 81: ...T WASHER Copyright 2003 ATSG Figure 135 Figure 134 COMPONENT REBUILD Center Support Assembly 9 If the sealing rings are the Hook joint type ensure that they are properly hooked and that theyrotatefree...

Page 82: ...ughlyusing a suitablecleaningsolution 3 Inspect all intermediate overdrive cylinder parts thoroughly for any wear and or damage 4 Remove and discard overdrive clutch molded piston and both intermediat...

Page 83: ...PISTON RETURN SPRING SNAP RING 38 OVERDRIVE CLUTCH PISTON RETURN SPRING 39 OVERDRIVE CLUTCH MOLDED PISTON ASSEMBLY 45 44 41 42 42 39 38 37 Figure 137 Figure 138 Figure 139 10 Install the overdrive cl...

Page 84: ...RT OVERDRIVE GEARSET EXPLODED VIEW Figure 140 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 84 COMPONENT REBUILD Overdrive Gearset Assembly 1 Disassemble overdrive gearset using F...

Page 85: ...ATSG 27 26 Ensure that snap ring is fully seated Figure 143 Figure 142 Figure 141 AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 85 Overdrive Gearset Assembly Cont d 6 Install thef...

Page 86: ...mber 6 thrust bearing onto the overdriveplanetarycarrierin the direction shown in Figure 144 10 Install completed overdrive planetary carrier into the pre assembled overdrive ring gear as shown in Fig...

Page 87: ...ENTER SHAFT ASSEMBLY 32 CENTER SHAFT TO RING GEAR WAVE SNAP RING 33 NUMBER 5 THRUST BEARING CENTER SHAFT TO SUPPORT Figure 147 Figure 146 32 33 30 COMPLETED OVERDRIVE GEARSET AUTOMATIC TRANSMISSION SE...

Page 88: ...yle Figure 148 Coast Clutch Housing Changes The coast clutch housing is model sensitive and there are three different versions as shown above The Cast Iron coast clutch housing is the same as the E4OD...

Page 89: ...13 COAST CLUTCH HOUSING ASM PTO VERSION SHOWN 14 OVERDRIVE ROLLER CLUTCH ASSEMBLY 15 COAST CLUTCH MOLDED PISTON 16 COAST CLUTCH PISTON RETURN SPRING ASSEMBLY 17 COAST CLUTCH PISTON RETURN SPRING SNAP...

Page 90: ...perpullersandpress SeeFigure150 Note Thisballbearingisnotavailablefrom Fordindividualy butisavailablefromyour localbearingsupplyunderKOYO6912C3 6 Placethecoastclutchhousingonaflatwork surface asshowni...

Page 91: ...stallpistonintothecoastclutch housing as shown in Figure 151 9 Install the coast clutch piston return spring assembly as shown in Figure 152 10 Compress the return spring assembly using a foot press a...

Page 92: ...clutch plates 18 With coast clutch plates removed install the pre assembledoverdrivegearsetontocoast clutch housing as shown in Figure 156 by rotatingcounter clockwiseuntilfully seated Note After ins...

Page 93: ...SEMBLY TOOL 307 S383 Copyright 2003 ATSG 18 19 20 21 13 COAST CLUTCH HOUSING ASM PTO VERSION SHOWN 18 COAST CLUTCH FRICTION PLATES 19 COAST CLUTCH STEEL PLATES 20 COAST CLUTCH BACKING PLATE 21 COAST C...

Page 94: ...UMP BODY TO CASE O RING SEAL 5 OIL PUMP INNER GEAR 6 OIL PUMP OUTER GEAR 7 STATOR SHAFT CONVERTER SEAL RING 8 STATOR SHAFT AND OIL PUMP COVER ASSEMBLY 9 COAST CLUTCH SEAL RINGS 2 REQUIRED 10 STATOR SH...

Page 95: ...ATOR BOOST VALVE 6 PRESSURE REGULATOR BOOST VALVE SLEEVE 7 PRESSURE REGULATOR BOOST VALVE SLEEVE SNAP RING 8 CONVERTER CLUTCH REGULATOR VALVE 9 CONVERTER CLUTCH REGULATOR VALVE SPRING 10 CONVERTER CLU...

Page 96: ...nd installation 6 Install new converter hub seal into the oil pump body as shown in Figure 161 using the proper drivers for removaland installation 7 Turn the oil pump body over and install inner and...

Page 97: ...n Copyright 2003 ATSG Figure 164 Figure 165 Figure 166 OIL PUMP COVER OIL PUMP STATOR SHAFT ASSEMBLY RETAINING BOLTS 3 COAST CLUTCH SEAL RINGS 2 Oil Pump Body And Cover Assembly Cont d 11 If removal...

Page 98: ...ly atthis time 18 Installtheoilpumpalignmentstrap asshown in Figure 169 and tightensecurely 19 Torquethe12pumpbodytopumpcoverbolts working in a criss cross pattern Torquethe bolts to 24 31 N m 18 23 f...

Page 99: ...2003 ATSG Copyright 2003 ATSG RF F81P 7A105 AA F o r d Copyright 2003 ATSG RF F81P 7A105 AA F o r d Copyright 2003 ATSG Figure 170 Figure 172 Figure 171 Figure 169 NUMBER 2A THRUST BEARING NUMBER 1 T...

Page 100: ...B 11 12 13 14 15 16 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 17 18 19 20 12 10 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Figure...

Page 101: ...ING CLIP BORE PLUG RETAINER 55 O D CLUTCH ACCUM REGULATOR PLUNGER BORE PLUG 56 O D CLUTCH ACCUM REGULATOR PLUNGER SPRING 57 O D CLUTCH ACCUM REGULATOR PLUNGER 58 O D CLUTCH ACCUM REGULATOR VALVE RETAI...

Page 102: ...nap ring into the reverse clutch hub as shown in Figure 174 and ensure it is fully seated Note The reverse hub may have to be raised up slightly to gain access to the snap ring groove in the reverse c...

Page 103: ...ng plate as shown in Figure 176 with the gaps in the steel plates at the 6 and 12 o clock positions in case 8 Install the intermediate clutch plates as shown in Figure 176 beginning with a friction pl...

Page 104: ...alignthefeedhole 14 Place the snap ring into the case and install the clutchspring compressortool 307 S223 as shown in Figure 180 and tighten the center bolt in the tool to 7 N m 65 in lb 15 Install t...

Page 105: ...urewouldbethesameasE4OD 20 Installtheoverdriveclutchpackintothecase asshowninFigure181 beginningwithasteel plateandalternatingwithfrictionplates until you haveinstalledtheproper amount Note The number...

Page 106: ...ousing and overdrive gearset as an assembly using the requiredinstallationtool307S383 asshown inFigure183 Ensurethatthenumber5thrust bearingisstillinplaceoncentershaft Caution The overdrive one way ro...

Page 107: ...oil pump to case gasket on case surface as shown in Figure 185 and use small amount of Trans Jel to help secure in place 32 Install the pre assembled oil pump assembly ensuring the number 2 thrust bea...

Page 108: ...so that bottom pan surface is facingup 39 Ensure thatnew feed bolts are used for center support and overdriveclutchcylinder 40 Torque overdrive clutch cylinder feed bolt to 8 14 N m 6 10 ft lb See Fig...

Page 109: ...SPACER PLATE 188 SPACER PLATE REINFORCING PLATE 189 REINFORCING PLATE RETAINING BOLT M6 X 1 0 X 42 3 1 Install eight 8 5 16 diameter checkballs in their case pockets as shown in Figure 188 2 Install...

Page 110: ...ockwise tolockinplace 7 Install the spacer plate to valve body gasket on spacer plate as shown in Figure 191 8 Install new O ring seal on the solenoid case connector as shown in Figure 192 lube the O...

Page 111: ...in control valve body 14 bolts two nuts the solenoid body 9 bolts one nut and reinforcing plate 3 bolts Note Refer to Valve Body Bolt Chart found on Page116for proper locations 14 Torque all valve bod...

Page 112: ...ANUAL SHIFT LEVERS 16 Install a new pan gasket on case surface as shown in Figure197 17 Install the bottom pan on top of pan gasket as shown in Figure197 18 Install the twenty 20 pan bolts as shown in...

Page 113: ...e the bolt to 8 10 N m 71 88 in lb 5 Install output shaft speed sensor if equipped as shown in Figure 201 and torque the bolt to 8 10 N m 71 81 in lb Note The TSS and OSS are model dependant 6 Install...

Page 114: ...spline end going in first 10 Lubricate the converter hub with Mercon fluid XT 2 QDX or equivalent as shown in Figure 204 11 Install torque converter and check the seating by placing a straight edge ac...

Page 115: ...ts 3 Overdrive Intermediate Cylinder Feed Bolt 1 Valve Body and Solenoid Body Bolts and Nuts All Spacer Plate Reinforcing Plate to Case 3 Detent Spring to Case 1 Inner Manual Valve Detent Lever Nut 1...

Page 116: ...e Nut 1 8 mm Head 8 mm Head Accum V B to Case Nut 2 Solenoid Body to Case Nut 1 8 mm Head 8 mm Head Accum Valve Body to Case 11 42mm Main Valve Body to Case 7 42mm Lower V B to Main V B 2 35mm 8 mm He...

Page 117: ...Pump Cover to Pump Body 9 45mm 9 8 J 10 mm Head Pump to Case 9 65mm 10 mm Head Oil Pan to Case 20 14mm 9 8 7 16 Head Case to Inner Race 5 1 875 Stator Shaft 3 17mm 30 Torx Head Center Support Hub 3 16...

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